Dodge 2005 Sprinter User manual

TABLE OF CONTENTS
1
2
3
4
5
6
7
8
9
1
3
4
5
6
7
8
9
2
10
10
SECTION PAGE
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
UNDERSTANDING THE FEATURES OF YOUR VEHICLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
UNDERSTANDING YOUR INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
STARTING AND OPERATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
WHAT TO DO IN EMERGENCIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
MAINTAINING YOUR VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
IF YOU NEED CONSUMER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

1
CONTENTS
INTRODUCTION
3 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 How to Use this Manual . . . . . . . . . . . . . . . . . . . . . . 5
3 Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . 5
3 Vehicle Identification Number, Sample
and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Vehicle Safety Certification Label, Sample
and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Vehicle/Engine Emission Label, Sample
and Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Environmental Concerns and
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Drinking Alcohol or taking Drugs
while driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Information Regarding Electronic
Recording Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 INTRODUCTION
INTRODUCTION
This manual provides information needed to operate
and understand the vehicle and its components.
Additional detailed information is contained in the
Owner’s Warranty Information Book and the Sprinter
Service Booklet.
Sprinter vehicles are equipped with a variety of
components. Not all of the information contained in
this manual applies to every vehicle.
IMPORTANT: Descriptions and specifications in this
manual were in effect at the time of printing.
For your reference, keep this manual in the vehicle at
all times.
DaimlerChrysler Vans LLC reserves the right to
discontinue models and to change specifications or
design at any time without notice and without
incurring any obligation. Descriptions and
specifications contained in this publication provide no
warranty, expressed or implied, and are subject to
revisions and publication of new editions without
notice.
WARNING!
Be sure to read the Operating Instructions. Other-
wise you may not be aware of certain risks and
could injur yourself or others.
WARNING!
Engine exhaust, some of its constituents, and cer-
tain vehicle components contain or emit chemi-
cals known to the State of California to cause
cancer and birth defects or other reproduction
harm. In addition, certain fluids contained in ve-
hicles, and certain products of component wear,
contain chemicals known to the State of Califor-
nia to cause cancer and birth defects or other re-
productive harm.

INTRODUCTION 5
1
HOW TO USE THIS MANUAL
Consult the table of contents to determine which
section contains the information you desire.
The detailed index, at the rear of this manual, contains
a complete listing of all subjects.
WARNINGS AND CAUTIONS
This manual contains WARNINGS against operating
procedures which could result in an accident or bodily
injury. It also contains CAUTIONS against procedures
which could result in damage to your vehicle. If you do
not read this entire manual you may miss important
information. Observe all Warnings and Cautions.
VEHICLE IDENTIFICATION NUMBER, SAMPLE
AND LOCATION
1. Vehicle identification number, visible (location:
lower edge of windshield)

6 INTRODUCTION
Vehicle identification number (location: on the chassis,
right hand).
VEHICLE SAFETY CERTIFICATION LABEL,
SAMPLE AND LOCATION
Location: below the driver’s seat on an outward facing
position of the mounting pillar.
1. Incomplete vehicle certification label for chassis/cab.
2. Type plate (vehicle identification number,
permissible weights)

INTRODUCTION 7
1
Sample Incomplete Vehicle Certification Label
(Label 1)
Sample Type Plate (Label 2)
VEHICLE/ENGINE EMISSION LABEL, SAMPLE
AND LOCATION
Location: on valve cover of the engine
Sample:
Important Engine Information
This is a LOW EMISSION VEHICLE engine and meets all applicable
requirements of US EPA CFFV as “ILEV” per 40 CFR 88 and CARB
as “ULEV” per CCR 1956.8
DaimlerChrysler AG, Stuttgart, Germany
Mercedes-Benz Engine, Model
Engine Family / Engine Code
Exhaust Emission Control
System
OM 647 LA CID 164
4 MBXH2.69DJB / Code I
TC, EMC, CAC, OC, EGR
Date of engine manufacture
Advertised output (SAE gr.)
Fuel rate at adv. Output
Valve lash cold (ins.)
Basic injection timing
Idle speed
2004
115 kW (154 HP) /3800 rpm
55 - 63 mm3/ stroke
n.a. int. / n.a. exh..
14.5 ± 1 degrees BTDC
680 ± 50 rpm
This engine conforms to US, EPA, CARB and Canada regulations
applicable to 2004 Model Year.
This engine has a primary intended service application as a light HD
diesel engine.
This engine is not certified for use in an urban bus as defined at 40
CFR 86.093.-2. Sales of this engine for use in an urban bus is a
violation of Federal Law under the Clean Air Act.
This engine is certified to be operated on diesel fuel.

8 INTRODUCTION
ENVIRONMENTAL CONCERNS AND
RECOMMENDATIONS
In this manual, whenever you see instructions to
discard materials, you should first attempt to reclaim
and recycle them. To preserve our environment, follow
appropriate environmental rules and regulations
when disposing of materials.
DRINKING ALCOHOL OR TAKING DRUGS WHILE
DRIVING
WARNING!
Drinking or taking drugs and driving can be a
very dangerous combination. Even a small
amount of alcohol or drugs can affect your reflex-
es, perceptions and judgement.
The possibility of a serious or even fatal accident
is sharply increased when you drink or take drugs
and drive.
Never drink or take drugs and drive or allow
anyone to drive after drinking or taking drugs.

INTRODUCTION 9
1
INFORMATION REGARDING ELECTRONIC
RECORDING DEVICES
(Including notice pursuant to California Code § 9951)
Please note that your vehicle is equipped with devices
that can record vehicle systems data.
This information helps, for example, to diagnose
vehicle systems after a collision and to continuously
improve vehicle safety. DaimlerChrysler may access
the information and share it with others
• for safety research or vehicle diagnosis purposes
• with the consent of the vehicle owner or lessee
• in response to an official request by law
enforcement or other government agency
• for use in dispute resolution involving
DaimlerChrysler, its affiliates or sales/service
organization and/or
• as otherwise required or permitted by law.
STICKERS
There are various warning stickers affixed to the motor
home. Their purpose is to make you and others aware
of various dangers.
WARNING!
Do not remove any warning stickers.
If you remove the warning stickers, you or others
may not be aware of certain dangers and could be
injured.

THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
2
CONTENTS
3 Ignition Lock/Starter Switch . . . . . . . . . . . . . . . . . 13
UImmobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Central Locking (Optional) . . . . . . . . . . . . . . . . . . 15
UUnlocking: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ULocking: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
UCentral Locking Switch 17
ULocking Status Display . . . . . . . . . . . . . . . . . . . . 18
ULocking and Unlocking . . . . . . . . . . . . . . . . . . . . 19
UTo Program the Automatic Lock Feature
when Starting the Engine . . . . . . . . . . . . . . . . . . 19
3 Remote Keyless Entry (Optional) . . . . . . . . . . . . . 20
UUnlocking with Remote Keyless Entry . . . . . . . 21
ULocking with Remote Keyless Entry . . . . . . . . . 22
3 Replacing Batteries in Remote Keyless Entry . . . 22
3 Security System with Towing and Passenger
Compartment Protection (Optional) . . . . . . . . . . . 23
UAudible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
UVisual Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
USwitching off the Alarm . . . . . . . . . . . . . . . . . . . 24
3 Towing Protection and Passenger Compartment
Protection Switch (Optional). . . . . . . . . . . . . . . . . . 24
UTowing Protection . . . . . . . . . . . . . . . . . . . . . . . . 24
USwitching off the Towing Protection . . . . . . . . . 24
UPassenger Compartment Protection . . . . . . . . . 25
USwitching off the Passenger Compartment
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
UAlarm Pushbutton (Vehicles with Security
Systems only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3 Opening/Closing doors . . . . . . . . . . . . . . . . . . . . . 27
USliding Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
URear Cargo Doors . . . . . . . . . . . . . . . . . . . . . . . . . 33
UPassenger/Cargo Area Door . . . . . . . . . . . . . . . 37
3 Occupant Restraints . . . . . . . . . . . . . . . . . . . . . . . . . 39

12 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
3 Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
USeat Belt Warning Lamp and Airbag
Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
UFastening and Removing . . . . . . . . . . . . . . . . . . 45
UBelt Height Adjustment . . . . . . . . . . . . . . . . . . . . 46
3 Driver’s Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3 Front Seat Passenger Airbag (not in conjunction
with folding seat in partition wall) . . . . . . . . . . . . 48
3 Airbag and Belt Tensioners . . . . . . . . . . . . . . . . . . 49
USRS Malfunction Indicator Lamp . . . . . . . . . . . 49
UBelt Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
USafety Precautions for the Airbag . . . . . . . . . . . 50
3 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3 Engine Break-In Specifications . . . . . . . . . . . . . . . . 52
UThe first 1,000 miles (about 1,500 km) . . . . . . . . 52
UEngine Oil Consumption 53
3 Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3 Inhalation of Exhaust Gas . . . . . . . . . . . . . . . . . . . . 54
3 Tie Down Rings (Optional) . . . . . . . . . . . . . . . . . . . 54

THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 13
2
IGNITION LOCK/STARTER SWITCH
0 The steering wheel is locked when the key is
removed
To remove the key, place the gear selector lever in
position "P"; rotate the key in the ignition lock to
position 0; and remove the key.
1 The steering wheel is unlocked
2 Preheating and driving position
3Startposition
To engage the steering wheel lock:
After removing the key, turn the steering wheel until
the steering wheel lock engages.
To release the steering wheel lock:
Turn the steering wheel slightly while turning the key
to position 1.
NOTE: If the driver’s or passenger’s door is opened
with the key in position 0 or 1 in the ignition lock, a
warning buzzer sounds.
WARNING!
Do not remove the key from the ignition lock un-
less the vehicle is stationary. Always remove the
key from the ignition lock when leaving the ve-
hicle to prevent children or unauthorized per-
sons from starting the engine.

14 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
Immobilizer
The immobilizer is automatically activated when the
key is removed from the ignition lock. The engine
cannot be started. As soon as the correct key is inserted
into the ignition lock, the immobilizer is deactivated.
For notes on the remote keyless entry, refer to "Remote
Keyless Entry".
NOTE: If the engine cannot be started and the displays
Áand îappear alternately in the multi-function
indicator when the key is in position 2 in the ignition
lock, a fault has developed or the key used has not been
activated.
Remove the key and repeat the starting procedure. If
the engine still cannot be started, consult an authorized
Sprinter Dealer.

THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 15
2
CENTRAL LOCKING (OPTIONAL)
To unlock (1)
To lock (2)
To unlock (1)
To lock (2)
CAUTION!
An unlocked vehicle is an invitation to thieves.
Always remove the key from the ignition and lock
all doors when leaving the vehicle unattended.
WARNING!
For personal security and safety in the event of an
accident, lock the vehicle doors when you drive
as well as when you park and leave the vehicle.

16 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
Unlocking:
If a door lock or interior handle on the driver or front
seat passenger door is unlocked, only the driver or
front seat passenger door will be unlocked.
NOTE: If a door lock or interior handle on the sliding
door or tailgate is unlocked, only the sliding door or
tailgate will be unlocked.
Locking:
All doors are automatically locked if a door lock or
interior handle is locked.
NOTE: If the central locking automatically unlocks
again after having been locked, at least one door is
closed incorrectly.
If it then locks again within about 5 seconds, then all
closed doors are locked.
The central locking displays vehicle locking with one
or more open doors by means of a special function
sequence (locking, unlocking, locking). Once closing
has been completed, an open door will not
automatically be locked.
WARNING!
When leaving the vehicle always remove the key
from the ignition lock, and lock your vehicle.
Do not leave children unsupervised in the vehicle,
even if they are secured by a child restraint system.
The children could
• injure themselves on parts of the vehicle
• release the child-proof locks by pressing the
central locking button and could thereby open
the doors and
• cause injury to others as a result
• get out of the vehicle and could either injure
themselves when doing so or they could be
injured by the traffic approaching from the rear
• suffer serious or fatal effects in the event of long
periods of hot weather
• release the parking brake. The vehicle could
then start moving of its own accord.
Unsupervised use of vehicle equipment may cause
severe personal injuries, death and property damage.

THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 17
2
After the engine is started (about 1 second), all doors
with the exception of the driver-side door are locked
automatically.
Central Locking Switch
The central locking switch is located
on the center section of the
dashboard.
The entire vehicle or just the
passenger door and the cargo doors
can be locked or unlocked from
inside the vehicle with the central locking switch.
After the engine is started (about 1 second), all doors
with the exception of the driver-side door are locked
(standard setting).
CAUTION!
In case of an accident, rescue from the outside may
be more difficult if the vehicle is locked.
To unlock the vehicle after the engine is started,
refer to "Central Locking Switch".

18 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
Locking Status Display
Left-hand indicator lamp is illuminated:
The driver’s door is locked.
Right-hand indicator lamp is illuminated:
Front-seat passenger door and rear-seat passenger
area/cargo area are locked.
Both indicator lamps are illuminated:
The entire vehicle is locked.
If an indicator lamp flashes:
At least one door has not been properly closed.
NOTE: The indicator lamps go out,
once the remote keyless entry transmitter has been
used to completely lock the vehicle;
if the ignition lock is in the position 0, and once the
interior handles/closing cylinders have been used to
completely lock the vehicle;
after about 15 minutes in position 0 in the ignition lock.
The display can be reactivated by pressing the central
locking switch, located on the center section of the
dashboard.
WARNING!
When leaving the vehicle always remove the key
from the ignition lock, and lock your vehicle.
Do not leave children unsupervised in the vehicle,
even if they are secured by a child restraint system.
The children could
• injure themselves on parts of the vehicle
• release the child-proof locks by pressing the
central locking button and could thereby open
the doors and
• cause injury to others as a result
• get out of the vehicle and could either injure
themselves when doing so or they could be
injured by the traffic approaching from the rear
• suffer serious or fatal effects in the event of long
periods of hot weather
• release the parking brake. The vehicle could
then start moving of its own accord.
Unsupervised use of vehicle equipment may cause
severe personal injuries, death and property damage.

THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 19
2
Locking and Unlocking
To lock entire vehicle:
Press top of central locking switch.
The left and the right indicator lamp in the switch
illuminate. If one of the two indicator lamps blinks, at
least one door is not closed properly.
To unlock entire vehicle:
Press top of central locking switch again.
To lock the front-seat passenger door and the rear-seat
passenger area/cargo area:
Press bottom of central locking switch.
The right indicator lamp in the switch illuminates. If
the indicator lamp blinks, at least one door is not closed
properly.
To unlock the front-seat passenger door and the rear-
seat passenger area/cargo area:
Press bottom of central locking switch again.
To Program the Automatic Lock Feature when
Starting the Engine
Place the key in position 2 in the ignition lock and close
all doors.
To switch off automatic locking of the front-seat passenger
door and the rear-seat passenger area/cargo area:
Press the central locking switch at the bottom and hold
it there for about 5 seconds. The right indicator lamp
flashes twice. Automatic locking when the engine is
started is switched off.
To switch on automatic locking of the front-seat passenger
door and the rear-seat passenger area/cargo area:
Press the central locking switch at the bottom and hold
it there for about 5 seconds. The right indicator lamp
CAUTION!
In case of an accident, rescue from the outside may
be more difficult if the vehicle is locked.
To unlock the vehicle after the engine is started,
refer to ‘‘Central Locking Switch’’.

20 THINGS TO KNOW BEFORE STARTING YOUR VEHICLE
flashes four times. Automatic locking when the engine
is started is switched on (standard setting).
NOTE: A door which is closed after the engine has
been started will not be locked automatically.
Au
Automatic Unlocking in Case of an Accident
The doors will unlock in the event of certain accidents,
provided that the power supply is still maintained.
REMOTE KEYLESS ENTRY (OPTIONAL)
NOTE: This device complies with Part 15 Subpart C
Section 231 of the FCC Rules. Operation is subject to
the following two conditions:
This device may not cause harmful interference, and
this device must accept any interference received
including interference that may cause undesired
operation.
NOTE: Any unauthorized modification to this device
could void the user’s authority to operate the
equipment.
NOTE: Included with your vehicle are 2 remote
keyless entry transmitters plus removable mechanical
key.
Keys which were not included with delivery must be
activated at an authorized Sprinter Dealer before they
can be used.
If a non-activated key is used, after the fourth attempt
to start, the starting process will be blocked for 1
minute.
The multi-function display will alternately show Á
and î, refer to "Immobilizer".
Malfunctions could occur if the remote keyless entry
transmitter is exposed to moisture. As a precaution,
both remote keyless entry transmitters should always
be carried.
CAUTION!
In case of an accident, rescue from the outside may
be more difficult if the vehicle is locked.
To unlock the vehicle after the engine is started,
refer to ‘‘Central Locking Switch’’.